Composite panels, articles incorporating same and method

Abstract

A composite panel is provided which includes a resin matrix having embedded therewithin alternating layers of particulates and flexible sheeting. The composite panel is capable of supporting its own weight and exhibits impact resistance and shatter resistance. Preferably, the resin is transparent, the particulates are decorative, and the flexible sheeting becomes transparent upon curing of the resin. The composite panels are included within articles such as tables, desks, other furniture, vertical partitions, decorative panels, doors, windows and floors. Also included is a method of making the composite panels by molding layers of these materials within an open mold.

I claim: 
     
       1. A composite panel, comprising: a resin matrix composed of a cured resin having transparency properties that allow for light passage therethrough;   a plurality of particulates embedded within and visible through said resin matrix;   a plurality of flexible sheets fully embedded within said resin matrix, said sheets being generally parallel to each other within the matrix, at least two of said sheets being spaced from each other, and at least one of said flexible sheets being located within the layer containing the particulates; and   said particulates, sheets and resin matrix combine to provide a composite panel laminate which supports its own weight and within which a plurality of said particulates are visible through the cured resin and flexible sheets.   
     
     
       2. The composite panel in accordance with claim 1, wherein a layer of said resin matrix is external of said flexible sheets. 
     
     
       3. The composite panel in accordance with claim 1, wherein said composite panel laminate includes: ordered layers of the cured resin, at least one flexible sheet, the cured resin with a plurality of said particulates therewithin, another said flexible sheet, and a layer of the cured resin. 
     
     
       4. A composite panel comprising: a resin matrix composed of a cured resin;   a plurality of particulates embedded within said resin matrix, said resin matrix having transparency properties such that said particulates are visible through the resin matrix;   a plurality of flexible sheets fully embedded within said resin matrix, said sheets being generally parallel to each other within the matrix, and at least two of said sheets being spaced from each other;   said particulates, sheets and resin matrix combine to provide a composite panel laminate which supports its own weight and within which a plurality of said particulates are visible; and   said composite panel laminate includes, in ordered layers: a layer of the cured resin, at least one of the flexible sheets, a combination of the particulates within said resin, at least another one of the flexible sheets as an intermediate flexible sheet, a composite of said particulates within the resin, at least a further one of the flexible sheets, and a further layer of the resin.   
     
     
       5. The composite panel in accordance with claim 1, wherein said particulates are glass chips, said flexible sheets are fiberglass fabric, and said cured resin is a transparent polymer. 
     
     
       6. The composite panel in accordance with claim 1, wherein said resin is selected from the group consisting of polyesters, epoxies, acrylic resins, polyester/acrylic resins and polyester/epoxy resins. 
     
     
       7. The composite panel in accordance with claim 1, wherein said particulates are selected from the group consisting of flakes and chips of glass, metal, wood and polymers. 
     
     
       8. The composite panel in accordance with claim 1, wherein said flexible sheets are selected from the group consisting of fiberglass fabric, glass fabric, glass mesh, metal mesh and polymer mesh. 
     
     
       9. The composite panel in accordance with claim 1, wherein said flexible sheets are fabric sheets. 
     
     
       10. The composite panel in accordance with claim 1, wherein said flexible sheets are mesh sheeting. 
     
     
       11. An article of manufacture comprising: a supporting member and a composite panel supported thereby, said composite panel including: a resin matrix composed of a cured resin having transparency properties which allow for light passage therethrough;   a plurality of particulates embedded within and visible through said resin matrix;   a plurality of flexible sheets fully embedded within said resin matrix, said sheets being generally parallel to each other within the matrix, at least two of said sheets being spaced from each other, and at least one of said flexible sheets being located within the layer containing the particulates; and   said particulates, sheets and resin matrix combine to provide a composite panel laminate which supports its own weight and within which a plurality of said particulates are visible through the cured resin and flexible sheets.     
     
     
       12. The article of manufacture in accordance with claim 11, wherein said article of manufacture is a piece of furniture, wherein said supporting member comprises a floor engaging member and a generally horizontal member which is maintained above the floor by said floor-engaging member. 
     
     
       13. The article of manufacture in accordance with claim 11, wherein said supporting member orients said composite panel in a horizontal orientation which is generally parallel to the floor. 
     
     
       14. The article of manufacture in accordance with claim 11, wherein said supporting member orients said composite panel in a vertical orientation which is generally perpendicular to the floor. 
     
     
       15. The article of manufacture in accordance with claim 11, wherein said composite panel laminate includes: ordered layers of the cured resin, at least one flexible sheet, the cured resin with a plurality of said particulates therewithin, another said flexible sheet, and a layer of the cured resin. 
     
     
       16. An article of manufacture comprising: a supporting member and a composite panel supported thereby, said composite panel including: a resin matrix composed of a cured resin;   a plurality of particulates embedded within said resin matrix, said resin matrix having transparency properties such that said particulates are visible through the resin matrix;   a plurality of flexible sheets fully embedded within said resin matrix, said sheets being generally parallel to each other within the matrix, and at least two of said sheets being spaced from each other;   said particulates, sheets and resin matrix combine to provide a composite panel laminate which supports its own weight and within which a plurality of said particulates are visible; and   said composite panel laminate includes, in ordered layers: a layer of the cured resin, at least one of the flexible sheets, a combination of the particulates within said resin, at least another one of the flexible sheets as an intermediate flexible sheet, a composite of said particulates within the resin, at least a further one of the flexible sheets, and a further layer of the resin.   
     
     
       17. The article of manufacture in accordance with claim 11, wherein said particulates are glass chips, said flexible sheets are fiberglass fabric, and said cured resin is a transparent polymer. 
     
     
       18. The article of manufacture in accordance with claim 11, wherein said resin is selected from the group consisting of polyesters, epoxies, acrylic resins, polyester/acrylic resins and polyester/epoxy resins. 
     
     
       19. The article of manufacture in accordance with claim 11, wherein said particulates are selected from the group consisting of flakes and chips of glass, metal, wood and polymers. 
     
     
       20. The article of manufacture in accordance with claim 11, wherein said flexible sheets are selected from the group consisting of fiberglass fabric, glass fabric, glass mesh, metal mesh and polymer mesh.